Shipping and display container with supporting insert

ABSTRACT

A one-piece shipping and display container is formed from a single unitary blank of corrugated paperboard. The one-piece shipping and display container includes opposed parallel side walls, opposed parallel end walls, bottom flaps, and top flaps all of which are foldably joined to one another for closing bottom and top portions of the one-piece shipping and display container. The one-piece shipping and display container includes a supporting insert panel that is removed from the container when the container is in a knock-down position. The supporting insert panel is inserted back into the container before or after the container is filled with products to provide protection for the products and further enhances the strength of the container during shipping and transportation.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. provisional patent applicationSer. No. 62/138,062, filed on 25 Mar. 2015, which is hereby incorporatedhereinto by reference as if fully restated herein.

FIELD OF THE INVENTION

This invention relates generally to shipping and display containers, andmore particularly to a shipping and display container having asupporting insert and supporting stacked products at a point of sale.

BACKGROUND OF THE INVENTION

Containers made of corrugated paperboard are commonly used for storingand shipping agricultural produce. Typically, such containers are formedfrom a blank scored with score lines and cut lines and have a bottom andopposed sidewalls. As used herein, the term “sidewalls” refers to theside walls extending along opposite sides of a container and the endwalls extending across opposite ends of a container. The term “sidewall” or “end wall” is used when a particular wall is intended. Theblanks are most often formed by automated machines in a continuousin-line process involving cutting, scoring and molding continuous sheetsof paperboard. The paperboard is then folded along the score lines andcut lines to form a container. The blanks may be folded into a containerby an automated machine or may be set up by hand. For stability instacking the containers it is common to have stacking tabs extendingupward from the top edge of the container sidewalls. These stacking tabsoften fit into corresponding notches cut into a superjacent container tohelp secure the stack. Since containers are usually stacked on top oflike-sized containers, the stacking tabs that extend upwardly from alower container are positioned directly into the sidewalls of asuperjacent container. Thus, to accommodate the stacking tabs on a lowercontainer, a complementary notch must be cut out of the bottom edge ofthe sidewall of a higher container.

Many retailers of agricultural produce and other commodities display andsell their products directly from the container they were shipped in. Todo this efficiently, retailers want containers to be strong enough toprotect their products during shipping and then can be converted quicklyand easily to display the products. The display feature or the window inthe container must show enough of the product to allow it to be readilyrecognized, and then easily removed from the container. To moreeffectively and efficiently utilize the shelf space in a retail store,retailers prefer to display the product from the narrow end of thecontainer. This makes the compromise between shipping strength and largedisplay area more difficult, as it often requires that the entire widthof the container be removed for display.

Corrugated paperboard or fiberboard that is usually used for this typeof container is generally produced in one of two container styles. Oneis the “Regular Slotted Container” or RSC that is the common style ofcontainer with four side walls and flaps to form the top and bottom.These are simple and economical. The other style is a “Tray”, with asolid bottom, often little or no top, and the side walls and end wallsare folded in to place by hand or glued on a machine. These are morecomplicated and more expensive trays. The claimed invention uses the RSCtype construction. The usual shortcoming of display RSC's is that inorder to facilitate the display and removal of the product, the strengthof this simple structure is severely compromised.

Therefore, it is desirable to have a shipping and display container witha supporting insert that significantly improves the strength andsimplicity of using it for packing agricultural and/or other products.

SUMMARY OF THE INVENTION

The claimed invention uses a simple and cost efficient RSC structure.The existing way to manufacture a display RSC's is to either cut out thedisplay window as scrap, or perforating its borders so that it can beseparated at the point of sale. Both of these options leave the shippingstrength of the container severely compromised. Cutting out the windowalso makes the product exposed. And perforating the borders is acompromise in and of itself. The more is cut to make it easier toremove, the more strength is removed for the shipping function. In thepresent invention, the material removed for display position is modifiedto become a supporting insert to be placed inside the container when itis being packed. In the knock-down position of the container prior topacking, the supporting insert remains attached to the container whicheliminates additional inventory. The placement of the insert providesprotection for the product in the container and substantially enhancesthe structural strength when compared to cutting out the window. Thissupporting insert is then easily removed at the point of sale to allowvery effective display and removal of the product from the container.

Preliminary testing shows that compared to a plain non-display RSC, onewith a cut out window on the end loses approximately 47% of it stackingstrength. One with a nicked in window loses about 36%, and the proposeddisplay containers with insert lost only 16%. Three samples of each weretested and averaged.

An advantage of the claimed invention is the simplicity of the structureof the container that allows laborers readily use it for packing ofagricultural produce and other products, either in field locations,packing houses, or manufacturing facilities. This container ismanufactured using a standard “flexo folder gluer” with minimalre-adjustment from a standard setup for a comparable RSC. At the packingsite, the packer or the person setting up the containers would detachthe supporting insert from the container by popping the nicks holdingthem together. The bottom flaps of the container are set up as with mostagricultural produce and many other products that are sold in thismanner. The supporting insert can be put in place either before, duringor after the product is packed in the container as preferred by thepacker. Finally, everything is held in place by the top flaps, closed inthe fashion common to agricultural produce and other commodities. At theretailer, the container is placed on the shelf, display table, orwherever they chose and the supporting insert is simply pulled outthrough the display window and recycled with other old corrugatedcontainers (OCC).

Accordingly, one aspect of the present invention is directed to aone-piece shipping and display container formed from a single unitaryblank of corrugated paperboard. The one-piece shipping and displaycontainer comprises opposed parallel side walls, opposed parallel endwalls, bottom flaps, and top flaps all of which are foldably joined toone another for closing bottom and top portions of the one-pieceshipping and display container. a supporting insert panel is removedfrom the container when the container is in a knock-down configuration.The supporting insert panel is inserted back into the container beforeor after the container is filled with products to provide protection forthe products and further enhances the strength of the container duringshipping and transportation.

Another aspect of the present invention is directed to a one-pieceshipping and display container formed from a single unitary blank ofcorrugated paperboard. The one-piece shipping and display containercomprises opposed parallel side walls having respective top and bottomflaps foldably joined to respective top and bottom ends thereof. Opposedparallel end walls are foldably joined to the side walls so that therespective top and bottom flaps are used for closing bottom and topportions of the one-piece shipping and display container. The one-pieceshipping and display container includes a supporting insert that isformed on one of the end walls and both of side walls or one of the sidewalls and both of end walls. The supporting insert is formed by threefrangible lines and is defined by first, second, and third frangiblelines intersecting one another. The supporting insert panel is removedfrom the container when the container is in a knock-down position. Thesupporting insert panel is inserted back into the container before orafter the container is filled with products to provide protection forthe products and further enhances the strength of the container duringshipping and transportation.

A further aspect of the present invention is directed to a blank formaking a shipping and display container which comprises a single unitarypiece of material cut and scored to define a plurality of parallelvertical folds delineating side wall panels, end wall panels, and a glueflap foldably joined to free edge of one of the side walls. Respectivetop and bottom flaps are foldably joined to respective longitudinaledges of the side walls. Each of the top flaps includes a single firstL-shaped slot forming in proximity of one end of the top flap. Each ofthe bottom flaps includes a pair of space-apart second L-shaped slotsforming in proximity of both ends of the respective bottom flaps.Respective depending flanges are foldably joined to respective lateraledges of the end walls. Two of the depending flanges include lockingtabs each of which is engaged with corresponding L-shaped slots when theblank is fully constructed. First, second, and third frangible lines areformed on the side wall and end wall panels to define a supportinginsert panel that is detached from the blank after the glue flap isattached to one of the end walls.

Other features may be incorporated, such as locating tabs, access holesfor insert removal, or clearance cutouts to match other features of thecontainer. These would not alter the purpose or function of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing, as well as other objects and advantages of the invention,will become apparent from the following detailed description when takenin conjunction with the accompanying drawings, wherein like referencecharacters designate like parts throughout the several views, andwherein:

FIG. 1 is a top perspective view of a shipping and display containerhaving a supporting insert in accordance to a preferred embodiment ofthe invention;

FIG. 2 is a top perspective view of the shipping and display containershown in FIG. 1 illustrating the supporting insert in a partially openposition;

FIG. 3 is a top perspective view of the shipping and display containershown in FIGS. 1 and 2 packed with products;

FIG. 4 is a top perspective view of the shipping and display containershown in FIG. 3 packed with products and in a display position;

FIG. 5 is a top plan view of one-piece blank B1 for making the shippingand display container shown in FIGS. 1-4;

FIGS. 6A-6C depicts the folding sequences of the one-piece blank B1 formaking the shipping and display container shown in FIG. 5;

FIG. 7 is a knock-down position of the of the shipping and displaycontainer shown in FIG. 1 with the supporting insert separated;

FIG. 8 is a top perspective view of a shipping and display containerhaving a supporting insert in accordance to an alternative embodiment ofthe invention;

FIG. 9 is a top plan view of one-piece blank B2 for making thealternative shipping and display container shown in FIG. 8; and

FIG. 10 is a knock-down position of the alternative shipping and displaycontainer shown in FIG. 8 with the supporting insert separated.

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible of embodiment in many differentforms, there is shown in the drawings and will herein be described indetail preferred embodiments of the invention with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the invention and is not intended to limit the broadaspect of the invention to the embodiments illustrated. In the presentinvention the use of prime character in the numeral references in thedrawings directed to the different embodiment indicate that thoseelements are either the same or at least function the same.

FIG. 1 is a top perspective view of a shipping and display container 10having a supporting insert 12 in accordance to a preferred embodiment ofthe invention. The container 10 is preferably rectangular configurationin a “Regular Slotted Container” or RSC with opposed parallel side walls14, 16; opposed parallel first and second end walls 18, 20; bottom flaps22, 24, and top flaps 26, 28 closing the bottom and top portions of thecontainer 10. In the claimed invention, the material that removed fordisplay configuration is modified to become a supporting insert 12 to beplaced inside the container 10 when it is being packed. In theknock-down configuration or position as shown in FIG. 6C the supportinginsert 12 remains attached to the container 10 which eliminatesadditional inventory. As depicted in FIG. 3, the placement of thesupporting insert 12 provides protection for the products in thecontainer and substantially enhances the structural strength whencompared to cutting out the window. This supporting insert 12 is theneasily removed at the point of sale to allow very effective display andfacilitates removal of the product from the container as illustrated inFIG. 4. As illustrated in FIGS. 3 and 4, the container 10 may includeoptional stacking tabs 30 each of which is formed on the respective topflaps 26 and 28.

During use, containers 10 are often stacked on top of one another forease of shipping and for optimum use of space. For stability in stackingthe containers it is common to have stacking tabs 30 extending upwardfrom the top edge of the container sidewalls 14 and 16. These stackingtabs 30 often fit into corresponding notches 32 cut into a superjacentcontainer to help secure the stack. Since containers 10 are usuallystacked on top of like-sized containers, the stacking tabs 30 thatextend upwardly from a lower container are positioned directly into thesidewalls of a superjacent container. Thus, to accommodate the stackingtabs 30 on a lower container, a complementary notch must be cut out ofthe bottom edge of the sidewall of a higher container.

FIG. 5 is a top plan view of one-piece blank B1 for making the shippingand display container shown in FIGS. 1-4. The one-piece blank B1 ispreferably an integral piece of a material such as continuous sheet ofconventional corrugated paperboard. The blank B1 is cut along its outermargins to form its specific shape so that corresponds to the shape ofthe shipping and display container 10 having the supporting insert 12.In this embodiment, the supporting insert 12 is formed substantially onthe end wall panel 20 and partially on the side walls 14 and 16. Theblank B1 is divided into side walls 14, 16 and end walls 18, 20 by threeparallel fold lines 34, 36, and 38. Moreover, the bottom flaps 22, 24,and the top flaps 26, 28 are also defined by two parallel longitudinalfold lines 46 and 48. A glue flap 47 foldably joined to the side wallpanel 16 and is defined by fold line 49. The widths of respective sidewall panels 14 and 16 are substantially larger than the widths of therespective end wall panels 18 and 20. This configuration provides theretailers to display the product from the narrow end of the container10. The supporting insert 12 is defined by three orthogonal frangiblelines defined by first, second, and third frangible lines 42, 40, and 44intersecting one another. The first frangible line extends transverselyacross one of the end walls and both of the side walls and each of therespective second and third frangible lines extends laterally on therespective opposed parallel side walls. Alternatively, the firstfrangible line extends transversely across one of the side walls andboth of the end walls and each of the respective second and thirdfrangible lines extends laterally on the respective end walls. Thesupporting insert 12 is delineated by frangible lines 40, 42, and 44.The central portion C of the supporting insert 12 is defined two foldlines 36 and 38 and a portion of the fold line 42. The left side L isdefined by fold line 36 and the frangible line 44 and a portion of thefold line 42. The right side R is defined by fold line 38 and thefrangible line 40 and a portion of fold line 42. It should be noted thatwhen the supporting insert 12 is removed, a major portion of the endwall panel 20 that is defined by frangible line 42 as well as a smallportion of the respective side walls 14 and 16 are also removed.

The supporting insert 12 includes a hand hole 61 that is used to pullout or remove the supporting insert. The two side wall panels 14, 16 aresubstantially the same and the respective top and bottom flaps 22, 24,26, and 28 are substantially the same as well. The side wall 14 includestwo spaced apart stacking tabs 30 a, 30 b formed on fold line 48 whichdefines the boundary of the side wall 14 and the top flap 26. The twospaced apart stacking tabs 30 a, 30 b are formed on the top end of theside wall 14. In addition, the side wall 14 includes two spaced apartnotches 32 a′, 32 b′ formed on fold line 46 which defines the boundaryof the side wall 14 and the bottom flap 22. The two spaced apart notches32 a′, 32 b′ are formed on the bottom end of the side wall 14.Similarly, the side wall 16 includes two spaced apart stacking tabs 30c, 30 d formed on fold line 48 which defines the boundary of the sidewall 16 and the top flap 28. The two spaced apart stacking tabs 30 c, 30d are formed on the top end of the side wall 16. In addition, the sidewall 16 includes two spaced apart notches 32 c′, 32 d′ formed on foldline 46 which defines the boundary of the side wall 16 and the bottomflap 24. The two spaced apart notches 32 c′, 32 d′ are formed on thebottom end of the side wall 16. When the blank B1 is fully constructed,the stacking tabs 30 a′, 30 b′ form the stacking tabs 30 as describedhereinbefore. The top flap 26′ includes an L-shaped slot 54 a and thebottom flap 22′ includes two spaced apart L-shaped slot 54 c which is asingle “L” lock to secure the top flap 26′. The shape of the slots isnot restricted to the L-shaped and can be other geometrical shapes asone of ordinary skilled in the art would appreciate it. The end wall 18′includes two opposed first depending flanges 50 a′ 50 b′ each whichfoldably extends from respective opposed lateral edges defined by foldlines 52 a′, 52 b′. The depending flange 50 a′ includes two firstlocking tabs 58 a′, 58 b′ each of which is engaged with correspondingL-shaped slots 56 b′ and 54 c′. Similarly, the depending flange 50 b′includes two rounded edges 59 a′, 59 b′ each of which is engaged withcorresponding L-shaped slots 54 a′ and 54 b′ which is a double “L” lockto secure the bottom flap. The end wall 20′ includes a second dependingflange 50 c′ which foldably extends from lateral edge defines by foldline 62. The second depending flange 50 c′ includes two second lockingtabs 60 a′, 60 b′ each of which is engaged with corresponding L-shapedslots 56 a′ and 54 d′. The respective wings 64 a′, 64 b′ fit under thetop flaps 26′ and 28′ to ensure the supporting insert 12′ is securely inplace.

FIGS. 6A-6C depicts the folding sequences of the one-piece blank B1 formaking the shipping and display container shown in FIG. 3. First, theside wall 16′ including the glue flap 47′ is folded 180 degree along thefold line 38 so that it coextensively lies onto the end wall panel 20′and side wall panel 14′. Next, adhesive is applied to the glue flap 47′and the end wall panel 18′ is adhesively attached to the tip of the glueflap 47′ as illustrated in FIG. 6C. Prior to erecting the blank B1, thesupporting insert 12 is separated from the blank B1 as illustrated inFIG. 7. Then, the bottom flaps 22′ and 24′ are brought together andlocked to one another to form the bottom wall of the container 10 andthe top flaps 26′ and 28′ are brought together and locked to one anotherto form the top wall of the container 10. It should be noted that inusing the container 10, the shipping and display container 10 is filledwith products and the supporting insert 12 is placed inside thecontainer and finally the top flaps 26′ and 28′ are brought together andlocked to one another to form the top wall of the container 10. At thepoint of sale, the retailer removes the supporting insert 12 so that theproduct is fully exposed for sale.

FIG. 8 is a top perspective view of a shipping and display container 10′having a supporting insert 12″ in accordance to an alternativeembodiment of the invention. FIG. 9 is a top plan view of one-pieceblank B2 for making the alternative shipping and display container shownin FIG. 8. FIG. 10 is a knock-down position of the alternative shippingand display container shown in FIG. 8 with the supporting insertseparated. In the alternative embodiment, the supporting insert 12″ isformed on the side wall rather than the end wall. Otherwise, the twoconfigurations principally functions and operate the same manner. Sincethe two configurations are principally the same, then the description ofBlank B1 is equally applicable to Blank B2 and the construction of thetwo blanks B1 and B2 are substantially the same. Applicant does notdescribe the blank B2 and the construction thereof to avoid redundancy.

While the invention has been described and illustrated with reference toone or more preferred embodiments thereof, it is not the intention ofthe Applicant that the invention be restricted to such detail. Rather,it is the intention of the Applicant that the invention be defined byall equivalents, both suggested hereby and known to those of ordinaryskill in the art, of the preferred embodiments. For example, thesupporting insert may be changed so that it contains different lengthand width corresponds to the size of the product contained therein.Moreover, the geometry of the side wall and end wall panels may bechanged so that it can carry more weight within the container. Thelocking tabs and attachments of the panels to one another may beconfigured differently so as to correspond to the retailer demands.

What is claimed is:
 1. A one-piece shipping and display container formedfrom a single unitary blank of corrugated paperboard, the one-pieceshipping and display container comprising: opposed parallel side walls,opposed parallel end walls, bottom flaps, and top flaps all of whichfoldably joined to one another for closing bottom and top portions ofthe one-piece shipping and display container wherein the one-pieceshipping and display container includes a supporting insert panel beingremoved from the container when the container being in a knock-downconfiguration and wherein the supporting insert panel being insertedback into the container before or after the container is filled withproducts to provide protection for the products and further enhances thestrength of the container during shipping and transportation.
 2. Theone-piece shipping and display container of claim 1 wherein thesupporting insert is formed substantially on one of the opposed parallelend walls and is delineated by frangible lines formed thereon.
 3. Theone-piece shipping and display container of claim 1 wherein thesupporting insert is formed substantially on one of the opposed parallelside walls and is delineated by frangible lines formed thereon.
 4. Theone-piece shipping and display container of claim 1 wherein thesupporting insert is formed by three orthogonal frangible lines definedby first, second, and third frangible lines intersecting one another. 5.The one-piece shipping and display container of claim 4 wherein thefirst frangible line extends transversely across one of the end wallsand both of the side walls and wherein each of the respective second andthird frangible lines extends laterally on the respective opposedparallel side walls.
 6. The one-piece shipping and display container ofclaim 4 wherein the first frangible line extends transversely across oneof the side walls and both of the end walls and wherein each of therespective second and third frangible lines extends laterally on therespective end walls.
 7. The one-piece shipping and display container ofclaim 1 wherein the top flaps and bottom flaps are foldably joined torespective top and bottom ends of the respective opposed parallel sidewalls.
 8. The one-piece shipping and display container of claim 1wherein each of the top flaps includes a single first L-shaped slotforming in proximity of one end of the top flap and wherein each of thebottom flaps includes a pair of space-apart second L-shaped slotsforming in proximity of both ends of the respective bottom flaps.
 9. Theone-piece shipping and display container of claim 1 wherein each of theopposed parallel end walls is defined by a first end wall and a secondend wall wherein the first end wall includes two opposed first dependingflanges each of which foldably extends from respective opposed lateraledges thereof and wherein the second end wall includes a single seconddepending flange that extends from a lateral edge thereof.
 10. Theone-piece shipping and display container of claim 9 wherein one of thefirst depending flanges includes a pair of first locking tabs each ofwhich is engaged with the respective L-shaped slots.
 11. A one-pieceshipping and display container formed from a single unitary blank ofcorrugated paperboard, the one-piece shipping and display containercomprising: opposed parallel side walls having respective top and bottomflaps foldably joined to respective top and bottom ends thereof andopposed parallel end walls being foldably joined to the side walls sothat the respective top and bottom flaps being used for closing bottomand top portions of the one-piece shipping and display container whereinthe one-piece shipping and display container includes a supportinginsert being formed on one of the end walls and both of the side wallsor one of the side walls and both of the end walls, the supportinginsert being defined by three frangible lines defined by first, second,and third frangible lines intersecting one another wherein thesupporting insert panel being removed from the container when thecontainer being in a knock-down position and wherein the supportinginsert panel being inserted back into the container before or after thecontainer is filled with products to provide protection for the productsand further enhances the strength of the container during shipping andtransportation.
 12. The one-piece shipping and display container ofclaim 11 wherein the first frangible line extends transversely acrossone of the end walls and both of the side walls and wherein each of therespective second and third frangible lines extends laterally on therespective opposed parallel side walls.
 13. The one-piece shipping anddisplay container of claim 11 wherein the first frangible line extendstransversely across one of the side walls and both of the end walls andwherein each of the respective second and third frangible lines extendslaterally on the respective end walls.
 14. The one-piece shipping anddisplay container of claim 11 wherein each of the top flaps includes asingle first L-shaped slot forming in proximity of one end of the topflap and wherein each of the bottom flaps includes a pair of space-apartsecond L-shaped slots forming in proximity of both ends of therespective bottom flaps.
 15. The one-piece shipping and displaycontainer of claim 11 wherein each of the opposed parallel end walls isdefined by a first end wall and a second end wall wherein the first endwall includes two opposed first depending flanges each of which foldablyextends from respective opposed lateral edges thereof and wherein thesecond end wall includes a single second depending flange that extendsfrom a lateral edge thereof.
 16. A blank for making a shipping anddisplay container, comprising: a single unitary piece of material cutand scored to define a plurality of parallel vertical folds delineatingside wall panels, end wall panels, and a glue flap foldably joined tofree edge of one of the side walls; respective top and bottom flapsfoldably joined to respective longitudinal edges of the side walls, eachof the top flaps includes a single first L-shaped slot forming inproximity of one end of the top flap and wherein each of the bottomflaps includes a pair of space-apart second L-shaped slots forming inproximity of both ends of the respective bottom flaps; respectivedepending flanges foldably joined to respective lateral edges of the endwalls wherein two of the depending flanges include locking tabs each ofwhich is engaged with corresponding L-shaped slots when the blank isfully constructed; and first, second, and third frangible lines areformed on the side wall and end wall panels to define a supportinginsert panel that is detached from the blank after the glue flap isattached to one of the end walls.